I'll comment on my observations from almost completely stripping the bike for a 40,000k service:
head off and valves & pistons look pretty clean
throttle bodies a bit gunked up so re-directed the crankcase breather
rear eccentric hub in good condition but replacing all the bearing & seals. Why wouldn't you?
slight scoring on the rear axle on cush drive side, more of a "discolouration" than scoring.
housing section in the swingarm for the rear hub needed a fair bit of cleaning up for clean rotation for chain adjustment
drop and drag link bearings & bushes were starting to look suspect. I think they will clean up ok but I had to scour some blemishes out of the bushing sleeves
I had already re-lubed my headstock bearings at 20,000 but have a tapered unit ready to go in next time I repace the fork oil
stock front caliper pistoin get a bit daggy at the exposed ends but what can you do? I've just recon'd some Tokico 6 pots to go in as my front pads were due anyway so we'll see what all the fuss is about re this mod
cush rubbers look fine but for $20 I have some coming
chain rubbing strip on swingarm is fine but for $25 why not? You won't know till you get it off
chain and sprockets are well on their way (1st set) but I won't try to squeeze another couple of thousand out of them

Hi all. I bought my '03 abou 4 years ago with around 40,000 miles. I was a bit concerned about the high mileage but I got a great deal. No major poblems so except for having to replace the stator at around 50 thou. I ride alot - especially high mileage road trips. Now at 65,000 miles it is still running strong. About 250 ml of oil use between changes (and only if I have been riding sportily). I just had the bike dyno tuned last summer which made a big diff in fuel consumption and power smothness. The dynotune guy found that the oxygen sensor was not working so he set the map at a neutral setting and eliminated the sensor from the system. He also found a blip at around 8000 rpm that showed on both the HP and torque graphs. I was surprised that he could not isolate the issue. I might try swapping out ignition coils. One of the changes that has had the biggest positive was changing the chan and sprockets. Last winter I lubed the whole rear end. This winter I will be changing out fork oil and checking the front end out. Also, one of my intake valve clearances is getting to the lower limit. Might need to reshim this winter. I'm hoping to get over 100,000 miles. Frequent oil and air filter changes are part of the plan. PS thanks for the endurance write-up Dave - very encouraging. - Jim

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